Structure forming method, apparatus and product

ABSTRACT

A method of forming a continuous composite structure includes encapsulating solid additive particles with a first reactive liquid resin forming material and migrating part of the mixture through a porous blanket to form a continuous resin matrix within the blanket with adhesive outer surfaces. A thin coating of a second preselected resin forming material which substantially cures immediately upon application is applied over one major adhesive upper surface of the matrix/blanket while allowing an area of the adhesive surface to remain exposed along one edge of the upper surface thereof. A plurality of preselected flexible lengths of the coated matrix/blanket are individually positioned successively in an overlapping orientation with the exposed adhesive area of the upper surface of the adjoining positioned length tightly affixed to the adhesive lower surface of the succeeding length to form a continuous composite structure. Also, the composite structure and apparatus for producing same.

This application is a continuation-in-part of pending Internationalapplication No. PCT/US98/23034, filed Oct. 30, 1998, which in turn is acontinuation-in-part of pending International application No.PCT/US96/15499, filed Sep. 26, 1996, which in turn is acontinuation-in-part of pending International application No.PCT/US96/05132, filed May 20, 1996, which in turn is acontinuation-in-part of International application No. PCT/US95/05450,filed May 4, 1995, now U.S. Pat. No. 5,725,716, which in turn is acontinuation-in-part of U.S. application Ser. No. 08/239,540, filed May9, 1994, now U.S. Pat. No. 5,496,434, which in turn is acontinuation-in-part of U.S. application Ser. No. 07/870,927, filed Apr.20, 1992, now U.S. Pat. No. 5,330,603, which in turn is acontinuation-in-part of U.S. application Ser. No. 07/753,344, filed Aug.30, 1991, now U.S. Pat. No. 5,145,282, which in turn is acontinuation-in-part of U.S. application Ser. No. 521,442, filed May 10,1990, now U.S. Pat. No. 5,049,006, which in turn is acontinuation-in-part of U.S. application Ser. No. 07/417,501, filed Oct.5, 1989, now U.S. Pat. No. 4,955,760, which in turn is acontinuation-in-part of U.S. application Ser. No. 07/235,205, filed Aug.23, 1988, now U.S. Pat. No. 4,872,784.

This invention relates to a novel continuous structure forming methodand apparatus and to a new continuous structure produced thereby.

The present invention provides a novel method, apparatus and structurewhich overcome the shortcomings of previous expedients. In addition, themethod, apparatus and structure provide features and advantages notfound in earlier technology.

The method and apparatus of the present invention may be employed byindividuals with only limited mechanical skills and experience.Structures can be produced by such individuals safely and efficientlywithout supervision utilizing the method and apparatus of the invention.

The method of the invention can be modified to form a variety ofdifferent structures with the apparatus of the invention. Variations inphysical dimensions, composition and surface appearance, etc. can beachieved. Even with such changes, uniform high quality can be maintainedwithout difficulty employing the method and apparatus of the presentinvention.

A novel method of the present invention for forming a substantiallycontinuous composite structure includes the steps of preselecting afirst liquid reactive resin forming material, a particulate solidadditive material and a porous blanket. The additive particles are mixedwith the first liquid resin forming material substantially continuouslyto form a substantially uniform mixture thereof. Substantially all ofthe additive particles are encapsulated with the first liquid resinforming material.

A porous blanket is advanced through the first liquid resin/additivemixture. Part of the mixture is migrated through the blanketsubstantially uniformly to form a continuous resin matrix within theblanket with the outer surfaces being adhesive.

A thin coating of a preselected second resin forming material whichsubstantially cures immediately upon application is applied to thematrix/blanket. The second resin forming material is applied oversubstantially one major adhesive upper surface of the matrix/blanketwhile allowing an area of the adhesive upper surface to remain exposedalong one edge of the upper surface.

A first preselected length of the coated matrix/blanket is positionedinto a preselected final configuration while it is flexible and has anadhesive lower surface and an exposed adhesive area along one edge ofthe upper surface thereof.

A second preselected length of the coated matrix/blanket is positionedin an overlapping orientation with the exposed adhesive area of thefirst positioned length of the coated matrix/blanket. The adhesive lowersurface of the second length is tightly affixed to the exposed adhesiveupper area of the first positioned length.

Thereafter, a plurality of additional lengths of the coatedmatrix/blanket individually in succession are positioned in anoverlapping orientation. Each adhesive lower surface of a coatedmatrix/blanket length being positioned is tightly affixed to the exposedadhesive upper area of the previously positioned length. The resultingsubstantially continuous composite structure has high strength andexceptional durability.

Advantageously, pressure is applied along the overlapped adhesivesurfaces of adjoining lengths of the coated matrix/blanket to form atight bond therebetween. Preferably, pressure is applied to theoverlapped adhesive surfaces immediatly upon the positioning of eachsucceeding length of the coated matrix/blanket. It is advantageous toapply rolling pressure to the overlapped adhesive surfaces.

In a preferred sequence, pressure first is applied along a leading edgeof a length of the coated matrix/blanket, followed by the application ofpressure at an intermediate point along the overlapped lengths.Thereafter, the intermediate application of pressure is changed torolling pressure along the overlapped adhesive surfaces oversubstantially the full length of the overlapped surfaces. It may bedesirable to cut the coated matrix/blanket to a preselected length afterthe full length has been positioned in its final configuration andpressure applied to the overlapped surfaces thereof.

Advantageously, the positioning of the coated matrix/blanket lengths andthe application of pressure to the overlapped areas is coordinated in apreselected sequence. With ditches of considerable width, the lengths ofthe coated matrix/blankets may be positioned across the ditch from oneside to the other.

Benefits and advantages of the novel method, apparatus and compositestructure of the present invention will be apparent from the followingdescription of the accompanying drawings in which:

FIG. 1 is a view in perspective of one form of mobile continuousstructure forming apparatus of the present invention;

FIG. 2 is a side view of the structure forming apparatus of theinvention shown in FIG. 1;

FIG. 3 is an enlarged fragmentary side view of the matrix formingportion of the structure forming apparatus of the invention shown inFIGS. 1 and 2;

FIGS. 4, 5 and 6 are schematic illustrations of the matrix/blanketpositioning portion of the structure forming apparatus of the inventionduring succeeding steps in the structure forming method of theinvention; and

FIG. 7 is a fragmentary view in perspective during the formation of acontinuous composite structure of the invention.

As shown in the drawings, one form of novel mobile continuous structureforming apparatus 11 of the present invention includes a supportingportion 12, a raw material supplying portion 13, a mixing portion 14, amatrix forming portion 15 and a control portion 16.

The supporting portion 12 of the structure forming apparatus of theinvention includes a plurality of spaced upstanding frame members20,21,22,23. The frame members are adjustable in length. A plurality ofgenerally horizontally disposed frame sections 25,26,27,28 join adjacentupper ends of the upstanding frame members. For example, as shown in thedrawings, frame section 25 extends between an upper end 30 of framemember 20 and an upper end 31 of frame member 21.

Opposed frame sections 25,27 are of adjustable length. This may beaccomplished as shown by dividing a frame section into two and partiallyoverlapping adjacent free ends within a housing 32, 33.

Spaced support sections 34,35 extend between opposed frame sections25,27 and particularly between the respective housing 32 or 33 of eachopposed frame section. Components of the material supplying portion 13as well as other components (not shown) such as an operator's seat, anelectrical generator, an air compressor, a hydraulic pump and the likealso can be mounted on and/or suspended from the frame sections andsupport sections.

Pivotable carriage means 36 extend downwardly from lower ends 37 of theupstanding frame members 20-23. Advantageously, the carriage meansinclude wheels 38 rotatable on axles 39. The carriages preferablyinclude variable drive means 41 and include endless track members 42.Drive means 41 advantageously adjust the length of frame members 20-23and adjustable frame sections 25,27. Preferably, the apparatus 11includes jack means 44 extending downwardly between the carriage means36.

The raw material supplying portion 13 of the apparatus 11 includes aplurality of reservoirs 46 operatively connected with the supportingportion 12. The reservoirs are connected independently with the mixingportion 14, preferably through flexible conduit means 47. The rawmaterial supplying portion advantageously also includes gravity feedhoppers 48 adjacent the mixing portion 14 and preferably heating meansalong the length of the conduit means.

The mixing portion 14 of the structure forming apparatus 11 of theinvention includes an elongated mixing chamber 49 adjustably disposed onthe supporting portion 12. The mixing chamber 49 preferably isinterconnected with a hopper 48 through an auger (not shown).

The matrix forming portion 15 of the apparatus 11 includes first mixturedistributing means 50 adjacent an outlet 51 of the mixing chamber 49 andadjustable downwardly therefrom. The first mixture distributing means 50as shown in the drawings includes a pair of spaced elongatedtransversely disposed arcuate members 52,53 disposed with generallyhorizontal lower edges adjustably oriented closer together than upperedges thereof.

The matrix forming portion also includes second mixture distributingmeans 54 adjacent the first mixture distributing means. The secondmixture distributing means advantageously is disposed in a generallyhorizontal orientation. Preferably, the second mixture distributingmeans includes a tubular member 55 with a narrow slot 56 along itslength disposed generally transversely of the movement of a blanketthrough the apparatus 11. Alternatively, the second mixture distributingmeans may include an orifice 57 mounted on a reciprocating cuttermechanism 58.

Positioning means 60 is disposed adjacent the second mixturedistributing means 54 for placement of a structure 59 in a preselectedfinal configuration while the structure is flexible and adhesive. Thepositioning means extends outwardly from the supporting portion 12. Asshown in the drawings, the positioning means includes a cantileveredframe assembly 61 extending from upstanding frame members 20,21 andpivotally connected thereto.

Positioning means 60 may include elongated structure grasping means 62translatably movable along the cantilevered frame assembly 61 extendingfrom the supporting portion 12. Advantageously, the elongated structuregrasping means 62 extends between and travels along spaced parallel siderails 63 of the frame assembly 61. The elongated structure graspingmeans 62 preferably includes a pair of cooperating hinged sections 64.The travel of the grasping means 62 advantageously is coordinated toequalize the tension across a structure being placed into a preselectedfinal configuration.

Pressure applying means 66 is disposed adjacent the positioning means60. The pressure applying means advantageously includes roller means 67which as shown may be disposed along one edge of the cantilevered frameasssembly 61. Preferably, the pressure applying means 66 includes spacedroller asssemblies 68-71 independently movable in a generally verticalplane. The pressure applying means 66 advantageously are disposed abovethe coated matrix/blanket 59 being advanced along the frame assembly 61.The operation of the pressure applying means preferably is coordinatedwith the travel of the elongated structure grasping means 62.

To form a continuous composite structure employing the method andapparatus of the invention as shown in the drawings, a first liquidreactive resin forming material is advanced from a reservoir 46 througha conduit 47 into mixing chamber 49. Simultaneously, other minoringredients e.g. colors, catalysts, etc. from other reservoirs (notshown) advance through conduits into the mixing chamber.

At the same time, a particulate solid additive material from a hopper 48enters the mixing chamber 49. The additive particles are mixed with thefirst liquid resin forming material substantially continuously,preferably in a proportion significantly greater than that of the resinforming material. During this mixing operation, substantially all of theadditive particles are encapsulated with the liquid resin formingmaterial to a preselected thickness.

The resulting mixture being delivered from outlet 51 of the mixingchamber 49 passes downwardly between arcuate members 52,53 into contactwith a porous blanket or blankets 43 moving therethrough. The mixture isdelivered at a rate sufficient to form a residual pool 45 between thearcuate members. As the blanket exits the liquid pool, part of themixture migrates through the blanket substantially uniformly to form acontinuous resin matrix within the blanket with the outer surfaces beingadhesive.

As the treated blanket passes the second mixture distributing means 54,a thin coating of a second resin forming material which curesimmediately is applied to the matrix/blanket. As shown in FIG. 1, thethin coating is applied over substantially one entire major adhesiveupper surface while allowing an area 72 of the adhesive upper surface toremain exposed along one edge of the of the upper surface.

The coated matrix/blanket then is advanced by grasping means 62 andplaced into a preselected final configuration such as a path or ditchwhile it is flexible and has an adhesive lower surface and an adhesivearea along one edge of the exposed upper surface with the remainderbeing a thin cured coating of the second resin forming material.Preferably, the adhesive lower surface is in contact with a firm basesurface such as concrete or packed soil or gravel.

As each length of the coated matrix/blanket is positioned to partiallyoverlap the previously positioned length, pressure is applied to theoverlapped area. Advantageously, this is accomplished with a pluralityof roller assemblies 68-71. These roller assemblies are spaced along oneedge of the cantilevered frame assembly 61. During the operation of thegrasping means 62, the rollers 67 are located above the matrix/blanket59 being advanced along the frame assembly.

When the matrix/blanket is properly positioned in its preselected finalconfiguration, each of the independently movable rollers 67 is moveddownwardly to engage the surface of the matrix/blanket. If thematrix/blanket is positioned over a ditch 78 as shown in FIG. 4, theroller assemblies 68 and 71 will pin the ends against the banks 79 ofthe ditch while roller asemblies 69 and 70 push the unsupported centerof the blanket against the sidewalls 80 and bottom 81 of the ditch (FIG.5). Next the roller assemblies 69,70 are moved along the overlapped areauntil the entire length thereof has been pressed tightly together and tothe ditch bottom.

Alternatively, when the leading edge of the matrix/blanket has beenplaced in its final configuration, roller assembly 71 can pin it to theditch bank before the length has been cut (FIG. 6). In this case, rollerassembly 70 can push the blanket against the ditch bottom followed byroller assembly 69 until the overlapped area is tightly pressed togetheragainst the ditch bottom and sidewalls. Finally, with roller assembly 68pinning the rear portion of the blanket to the bank, the cutter 58 isactivated to cut the matrix/blanket precisely into the required length.

Thereafter, additional lengths 73 of the coated matrix/blanket areindividually positioned in succession into an overlapping orientation(FIG. 7). The lower adhesive surface of the length being positioned istightly affixed to the exposed adhesive area 72 of each previouslypositioned length by applying pressure to the overlapped adhesivesurfaces with rollers 68-71. As shown, each length of the coatedmatrix/blanket is positioned in overlapping succession to form asubstantially continuous composite structure with high strength andexceptional durability.

To produce high quality continuous composite structures of theinvention, it is important that all of the steps be carefullycoordinated by control portion 16. The control portion 16 of thestructure forming apparatus 11 of the invention includes programmablememory means 74 and actuating means 75 responsive thereto in combinationwith coordinating means 76 to control the operation of the variouscomponents of apparatus 11. Preferably, the coordinating means includesa process controller 77 that initiates changes in the flows of materialsand speeds of drives to bring variations therein back to the ratesspecified in the programs present in the memory 74.

This coordination commonly is achieved through the transmission ofinformation such as digital pulses from monitors and/or sensors at thecontrol components to the process controller 77. The operatinginformation is compared with the preselected programming parametersstored in the memory 74. If differences are detected, instructions fromthe controller change the operation of the components to restore thevarious operations to the preselected processing specifications.

The above procedure provides a substantially continuous multilayercomposite structure with a thin layer of an instanteously cured secondresin over a continuous first resin rich upper layer over a thickercentral layer including a plurality of encapsulated solid particles e.g.gravel, particles from grinding discarded tires etc., within acontinuous first resin matrix. The resin matrix extends throughout thestructure from the resin rich upper layer through the particle richcentral layer downwardly through blanket 43 and into a resin rich lowerlayer including a few very small solid particles disposed primarilyclosely adjacent to the blanket.

Normal maneuvering of the continuous structure forming apparatus of theinvention to maintain it close to a preselected path ordinarily can beaccomplished by increasing the speed of the carriages 36 on one sideand/or decreasing the speed of the carriages on the other side. Majortransverse changes of direction may be accomplished by pivoting thecarriages 36 ninety degrees from the normal operating orientation usingjacks 44 to raise the carriages off the ground. The apparatus then ismoved sideways into a desired position at which point, the jacks 44again raise the carriages 36 so they can be pivoted back to anorientation parallel to its original position.

The same steps can be employed to move the apparatus around obstaclessuch as bridges, trees, head gates, etc. To change the width of theapparatus, the two carriages on one side can be pivoted and driven awayfrom or toward the center of the apparatus and thereby lengthen orshorten the adjustable frame sections 25, 27.

The reactive resin forming materials employed to produce compositestructures of the invention are selected to be capable of reaction toform the particular resin matrix or coating desired in the finalstructure. Advantageously, the materials form thermosetting resins suchas a polyurethane or polyester. Should a polyurethane be desired, onereservoir may contain an isocyanate and another reservoir may contain apolyol.

More commonly, the reservoirs may contain different partially formedmaterials which upon mixing interact to form the desired polyurethane.Examples of such partially formed materials include so-called “A stage”resins and “B stage” resins.

Other resin forming systems may utilize a resin forming material in onereservoir and a catalyst in a second reservoir. Additional componentscan be premixed with one of the resin formers, e.g. fillers,reinforcements, colors and the like.

The particulate solid additive material is mixed with the first liquidreactive resin forming material substantially continuously, preferablyin a proportion significantly greater than that of the resin formingmaterial. The additive particles may be any of a wide variety ofinexpensive materials readily available at a particular job site.Natural mineral particulate materials such as sand and gravel normallyare available or can be produced simply by crushing rock at the site.

Also, materials such as waste or recycled materials which can beshredded or ground into particles of suitable size can be utilized.Particularly useful are particles formed by shredding or grindingdiscarded tires. Since the particles are encapsulated with the firstresin forming material and not saturated therewith, many different wastematerials may be employed.

Suitable porous blankets include woven, knit, non-woven structures, etc.The blankets e.g. fabrics, mats, etc. may be formed of continuous ordiscontinuous fibers, yarns, slit ribbons and similar natural andsynthetic fibrous materials. Reinforcing members such as ropes, cablesand the like that extend longitudinally and/or transversely of theblanket centerline may be included if desired.

The above description and the accompanying drawings show that thepresent invention provides a novel method, apparatus and compositestructure which overcome the shortcomings of previous expedients and inaddition, provide features and advantages not found in earliertechnology.

The composite structure produced with the method and apparatus of theinvention can include major proportions of recycled, waste or othermaterials which are readily available at a job site. These structuresare of high quality and may exhibit properties not usually found inproducts formed with conventional ingredients.

The method of the invention may be conducted by individuals with onlylimited mechanical skills and experience to produce high qualitystructures safely and efficiently. The method can be modified to form avariety of different structures. Variations in configuration,composition, physical dimensions and surface appearance, etc. can beachieved easily. Even with such changes, uniformity and high quality canbe maintained without difficulty.

It will be apparent that various modifications can be made in theparticular method, apparatus and composite structure described in detailabove and shown in the drawings within the scope of the presentinvention. The method steps, apparatus components and types of materialsemployed can be changed to meet specific process and structuralrequirements.

These and other changes can be made in the method, apparatus andcomposite structure of the invention provided the functioning andoperation thereof are not adversely affected. Therefore, the scope ofthe present invention is to be limited only by the following claims.

What is claimed is:
 1. A method of forming a continuous compositestructure including the steps of preselecting a first liquid reactiveresin forming material, a particulate solid additive material and aporous blanket, mixing said additive particles with said first liquidresin forming material substantially continuously to form asubstantially uniform mixture thereof, encapsulating substantially allof said additive particles with said first liquid resin formingmaterial, advancing said porous blanket through said liquidresin/additive mixture, migrating part of said mixture through saidblanket substantially uniformly to form a continuous resin matrix withinsaid blanket with adhesive outer surfaces, preselecting a second resinforming material which substantially cures immediately upon applicationand is compatible and reactive with said adhesive first resin formingmaterial, applying a thin coating of said second resin forming materialover substantially one major adhesive upper surface of saidmatrix/blanket while allowing an area of said adhesive surface to remainexposed along one edge of said upper surface thereof, positioning afirst preselected length of said coated matrix/blanket into apreselected final configuration while it is flexible and has an adhesivelower surface in contact with a firm base surface and an exposedadhesive area along one edge of said upper surface thereof, positioninga second preselected length of said coated matrix/blanket in anoverlapping orientation with said exposed adhesive area of said firstpositioned length of said coated matrix/blanket, tightly affixing saidadhesive lower surface of said second length to said exposed adhesivearea of said first length and the remaining portion of said adhesivelower surface to said firm base surface, and successively positioningand tightly affixing together a plurality of additional lengths of saidcoated matrix/blanket in overlapping orientation to form a substantiallycontinuous composite structure with high strength and exceptionaldurability tightly affixed to said firm base surface.
 2. A method offorming a continuous composite structure according to claim 1 includingthe step of applying pressure along said overlapped adhesive surfaces ofadjoining lengths of said coated matrix/blanket to form a tight bondtherebetween.
 3. A method of forming a continuous composite structureaccording to claim 2 wherein pressure is applied along said overlappedadhesive surfaces immediately upon the positioning of each succeedinglength of said coated matrix/blanket in an overlapped relationship.
 4. Amethod of forming a continuous composite structure according to claim 2including applying rolling pressure to said overlapped adhesivesurfaces.
 5. A method of forming a continuous composite structureaccording to claim 2 wherein pressure first is applied along a leadingedge of said length of said coated matrix/blanket, followed by applyingpressure intermediate of said length, and changing said intermediatepressure to rolling pressure along said overlapped adhesive surfacesover substantially the full length thereof.
 6. A method of forming acontinuous composite structure according to claim 1 including the stepof positioning said coated matrix/blanket lengths across a ditch.
 7. Amethod of forming a continuous composite structure according to claim 2wherein said positioning of said coated matrix/blanket lengths andapplying pressure thereto are coordinated in a preselected sequence. 8.Mobile continuous structure forming apparatus including a supportingportion, a raw material supplying portion, a mixing portion, a matrixforming portion and a control portion; said supporting portion includinga plurality of spaced upstanding frame members of adjustable length, aplurality of generally horizontally disposed frame sections joiningadjacent upper ends of said upstanding frame members, one pair ofopposed frame sections being of adjustable length, support sectionsextending between said adjustable opposed pair of said frame sections,pivotable carriage means extending downwardly from lower ends of saidupstanding frame members; said raw material supplying portion includinga plurality of reservoirs operatively connected with said supportingportion, said reservoirs being connected independently with said mixingportion; said mixing portion extending from said supporting portion,said mixing portion including an elongated mixing chamber adjustablydisposed adjacent said supporting portion; said matrix forming portionincluding first mixture distributing means extending adjustablydownwardly from said mixing chamber and being disposed adjacent anoutlet thereof, second mixture distributing means disposed adjacent saidfirst mixture distributing means, positioning means disposed adjacentsaid second mixture distributing means for placement of a structure in apreselected final configuration, pressure applying means disposedadjacent said positioning means; said control portion includingprogrammable memory means, coordinating means, sensing means, actuatingmeans, and circuitry transmitting signals from said sensing means tosaid coordinating means for comparison with said memory means andactivation of said actuating means to form and place a continuousstructure into a preselected final configuration while it is flexibleand adhesive.
 9. Mobile continuous structure forming apparatus accordingto claim 8 wherein said pressure applying means includes roller means.10. Mobile continuous structure forming apparatus according to claim 8wherein said positioning means includes sensing means and actuatingmeans.
 11. Mobile continuous structure forming apparatus according toclaim 8 wherein said positioning means extends from said supportingportion.
 12. Mobile continuous structure forming apparatus according toclaim 11 wherein said positioning means includes elongated structuregrasping means translatably movable along a generally horizontallydisposed frame section.
 13. Mobile continuous structure formingapparatus according to claim 12 including pressure applying meansdisposed along one edge of said frame section.
 14. Mobile continuousstructure forming apparatus according to claim 9 wherein said pressureapplying means includes spaced roller means independently movable in avertical plane.
 15. Mobile continuous structure forming apparatusaccording to claim 14 wherein at least one of said roller means includesreversible driven roller means.
 16. Mobile continuous structure formingapparatus according to claim 12 wherein said elongated structuregrasping means includes a pair of cooperating hinged sections. 17.Mobile continuous structure forming apparatus according to claim 16wherein said elongated structure grasping means extends between andtravels along spaced parallel side rails of said frame section. 18.Mobile continuous structure forming apparatus according to claim 17including control means coordinating the travel of said elongatedstructure grasping means to equalize the tension across a structurebeing advanced along a preselected path.
 19. Mobile continuous structureforming apparatus according to claim 12 including control meanscoordinating the operation of said pressure applying means with thetravel of said elongated structure grasping means.